By Eileen Harvey
In today’s industrial landscape, reliable and efficient control systems are essential for keeping operations running smoothly. Multi-conductor flexible control cables have become a vital part of automation, providing the backbone for communication and power distribution among machines and equipment. Built with flexibility and durability in mind, these cables are engineered to perform in complex environments where machinery is in constant motion.
What makes these cables so valuable is their ability to combine multiple conductors inside a single protective sheath. This design streamlines installation, reduces wiring clutter and allows for more efficient use of space. Their robust construction also shields them from moisture, chemicals and mechanical stress, which are common in manufacturing and production settings.
This article explores what multi-conductor flexible control cables are, their importance in industrial automation, the key applications where they excel, the advantages they bring, and how to select the right option. It also provides practical guidance on cable tips and recommendations to help businesses reduce downtime and optimize long-term performance.
What Are Multi-Conductor Flexible Control Cables?
A multi-conductor flexible control cable is an electrical cable containing multiple insulated conductors bundled together under a single protective jacket. These cables are specifically designed for applications where flexibility, durability and space-saving are critical.
These cables have three distinctive traits. First, they are multi-conductor, with multiple insulated wires that allow simultaneous transmission of power, control signals or data. Second, they are flexible, with stranded copper conductors and high-quality insulation that allow repeated bending without damage. The third trait of these cables is control, as they are typically used in automation and machinery for transmitting signals between controllers, motors, sensors and actuators.
Importance in Industrial Automation
Industrial automation environments require reliable cables that can withstand harsh operating conditions. Constant motion is one, as robotic arms, conveyor systems and drag chains demand cables that can bend thousands of times daily without breaking. Electrical noise resistance is another common condition. Many flexible control cables include shielding to protect signals from EMI (electromagnetic interference). Space efficiency is another feature required of these cables. Multi-conductor designs minimize wiring bulk and simplify installation. Safety and compliance is a fourth feature, as these cables are designed to meet standards such as UL, CSA and IEC for industrial use.
Key Applications
Let’s look at five popular applications of multi-conductor flexible cables used in industrial automation. First is robotics, with precise control and continuous movement demanding cables like theKaweflex 6110 5-Conductor 18 AWG for transmitting both power and control signals. Second is CNC machines, as cables route control signals to servos and drives, ensuring precision machining. A third application is packaging and assembly Linesꟷflexible cabling supports high-speed repetitive tasks without downtime.
A fourth common application is drag chains and cable tracks; products like theKaweflex 6210 Shielded 4-Conductor 16 AWG are ideal for environments with heavy EMI and constant motion. A fifth application is control panels, as multi-core cables simplify wiring, reduce clutter and improve reliability.
Advantages of Multi-Conductor Flexible Control Cables
Let’s consider the five main advantages. First is durability, cables engineered for millions of bending cycles. Second is signal Integrity, since shielded versions protect against noise. A third advantage is space and cost savings, because fewer separate wires mean cleaner installations. Fourth is versatilityꟷthese cables are available in 2 to 25 conductors (e.g.,25-Conductor 18 AWG Kaweflex 6110). And a fifth advantage is compliance, with UL/CSA ratings ensuring safety in industrial use.
Shielded vs. Unshielded Versions
When selecting flexible control cables, shielding plays a key role. Unshielded versions (e.g.,Kaweflex 6110 12-Conductor 16 AWG) are suitable for power transmission or low-noise environments. Shielded versions (e.g.,Kaweflex 6210 Shielded 4-Conductor 14 AWG) are best for automation systems with sensitive signals where EMI is a concern.
Tips for Choosing the Right Cable
Selecting the right cable begins with matching the conductor size to the current requirements, such as 21 AWG for signals and 16 AWG or 14 AWG for higher power. The number of conductors should also be considered, since higher counts simplify multi-signal applications. In noisy industrial environments, shielding is critical, making shielded versions the better choice for ensuring signal integrity. Installation factors such as bending radius should not be overlooked, especially for use with robotic arms or drag chains where repeated movement is constant. Finally, it is wise to think ahead and choose a cable with extra conductors to allow for future upgrades.
Useful Facts
In addition, keep in mind three facts. First, multi-conductor cables can reduce wiring installation time by up to 50%. Second, a single flexible control cable can replace dozens of separate wires in a control cabinet. Third, L-com’s TKD Kaweflex series supports over 10 million bending cycles, making them perfect for robotic applications.
Recommendations
The right choice depends on the environment and the type of system being supported. For basic drag chain power and control, the Kaweflex 6110 Series is a strong option, such as the 4-Conductor 18 AWG. In applications where electromagnetic interference is present, the shielded Kaweflex 6210 Series provides superior protection, with versions like the Shielded 5-Conductor 18 AWG well suited for harsh conditions. High-density control systems benefit from cables with larger conductor counts, such as the 25-Conductor Kaweflex 6110 21 AWG, which consolidates wiring and simplifies installations.
Multi-conductor flexible control cables remain a foundation of industrial automation. By combining durability, flexibility and versatility, they reduce downtime, simplify wiring and support reliable machine performance. Whether the need is for unshielded cables in drag chains or shielded ones in EMI-heavy environments, the Kaweflex 6110 and 6210 Series from L-com deliver solutions that meet demanding requirements. With conductor counts ranging from 2 to 25 and gauges from 14 AWG to 21 AWG, there is a cable suited for nearly every industrial application, ensuring both efficiency and long-term reliability.
